Operating / Installation Instructions

40A DC TO DC BATTERY CHARGER

80A When combined with Start Assist Booster Kit (ISABK001)
The IDCDC40 is able to utilise 40A when wired with a standard
configuration and up to 80A charging to the auxiliary battery using
our new boost mode (kit supplied separately). This is all still acheived
in an extremely compact package (373cm³) while still boasting all
the features of a booster battery charger in a weather, dust and
vibration resistant package.

Features
• 3-stage 12V Booster Charger
• 40A max output TECHNICAL DATA
• Selectable output voltages Max Charge Current (without Boost Kit) 40 Amps
Max Charge Current (with Boost Kit) 80 Amps
• Over current and temp protected Input Op Volt Range 11-16VDC
• Precise under voltage protection Max Charge Voltage
(Flooded Cell) 14.5V
No external isolator required
(Lithium) 14.8V
• High efficiency (Typically >96%) (AGM/GEL) 14.3V
Float Voltage: 13.5V
• Remote charge status LED indicator Lithium Float Charge: 13.9V
• Very low standby current <3mA Standy Current: 0.003A
Min Input Startup Volt: 12V
• Optional start assist and boost charge features Dimensions: 162x71.5x32.2mm
Weight: 560g
increased amperage output to 80A max

Important Notes
• Before installation the user shall determine the suitability of the product to ensure correct application.
• Check with your battery manufacturer for the suitability of the charger for your installation.
• Where Lithium battery banks are involved ensure your Battery Management System (BMS) is compatible with our charger.
• A large spark can sometimes be generated during connection, due to the current required to charge the capacitors
in the charger.
• Do not short out when powered and operational, as this may cause damage to the unit.
• If the Start Assist / Boost Charge option is not used and the solenoid is not installed then please leave the yellow wire
unconnected and isolated.

Installation
• Disconnect the battery supply.
• The following connection sequence is to be followed: Ground (BLACK), Input (RED), Output (BROWN),LED (GREEN),
Chemistry/Output Selection (ORANGE), Control (BLUE).
• The unit is protected from weather and dust but do not pressure wash or mount to areas that will be submerged. Avoid
locations such as fuel lines or where external heat is produced e.g. exhaust system or where the batteries are located.
• Chose a position with good ventilation where air can pass freely around the unit.
• Ensure the unit is protected from sources of contamination e.g. oil, grease and dust.
• Ensure that the unit is installed away from any flammable fumes, liquids or materials.
• If you are installing to use the Start Assist/Boost Charge feature we recommend that the solenoid is mounted as close
to the charger as per wiring diagram overleaf.

www.ironman4x4.com PART NO: IDCDC40

 Operating / Installation Instructions

40A DC TO DC BATTERY CHARGER

80A When combined with Start Assist Booster Kit (ISABK001)

WIRING GUIDE FOR STANDARD INSTALLATION LED Indications

ON / Solid
No Start Assist Max 40A Output Normal Operation
During normal operation the Remote LED
FUSE RATINGS will remain solid ON as a indication of
Fuse 1 50A normal charging.
Chemistry Selection
Fuse 2 50A
S
To Ground Flooded Cell Slow Flashing
NOTE: Fuses not supplied To 12V+ Lithium
Floating AGM/GEL YELLOW - Tape Up Auxiliary Below 12VDC
A flashing LED is a visual indication that
Floating / No Connection the Auxiliary Battery is below 12V.
LED
12+
OFF
To Ignition Switch of Vehicle ORANGE No Output / Check
The LED is completely blank is indicative of No
GREEN Output from the unit and can be from several
BLUE conditions:
BROWN RED • That the ignition has been turned off and the
FUSE 1 FUSE 2 BLUE ignition wire is at 0V.
• Fuse 2 may be blown - Check Fuse 2 and
replace if required.
• Over Temperature - No action required. Unit will
restart when temperature drops within normal
AUXILARY MAIN operating range.
BATTERY BLACK BATTERY
12V 12V
F Fast Flashing
Following a failed cranking
• Start Assist Activated - Check main battery
• If occurs outside of cranking during normal
WIRING GUIDE FOR OPTIONAL START ASSIST operating - Return unit for recalibration.
Boost up to 80A Output Chemistry Selection
To Ground Flooded Cell
To 12V+ Lithium
Start Assist and Boost Charge
FUSE RATINGS Floating AGM/GEL

Floating / No Connection Start Assist

Fuse 1&2 100A 12+ With the solenoid connected it enables the unit to
Fuse 3&4 50A ORANGE automatically provide assistance from the Auxiliary
NOTE: Fuses not supplied LED Battery on starting of the vehicle. Provided the
Auxiliary Battery is charged. Following a failed
BLUE
To Ignition Switch of Vehicle
cranking attempt due to low main battery charge-
BROWN Release the key so it returns to “ON” position, do
GREEN
not bring it to the “OFF” or “ACC” position. Now
RED within a couple of seconds try cranking again. The
BLACK
FUSE 3

FUSE 4

vehicle will then start and the LED indicator will

RED with Black Tip RED flash rapidly for about 60 seconds. Following the
100A> Rated Cable 100A> Rated Cable Start Assist activation and fast LED flashing we
recommend having your main battery and wiring
Signal Wire
tested.
FUSE 1

BROWN YELLOW
FUSE 2

Boost Charge
With the addition of the solenoid boost charge will
allow up to 80A initial charge for fast flat auxiliary
Solenoid battery charging conditions. This initial boost
AUXILARY MAIN charge reverts automatically to normal charging
BATTERY BLACK BATTERY once the auxiliary recovers from deep discharge.
12V 12V
NOTE: 100A or greater rated cabling must be used between solenoid and batteries

Warranty Conditions: Our products come with guarantees that cannot be excluded under the Australian Consumer Law. The customer is entitled to a replacement or refund for
a major failure and compensation for any other reasonably foreseeable loss or damage. The customer is also entitled to have the products repaired or replaced if the products
fail to be of acceptable quality and the failure does not amount to a major failure. Ironman 4x4 warrants that its products will, under normal use and service, be free of defects
in material and workmanship for a period of two (2) years from the date of the original purchase by the customer as marked on the customer’s original invoice. Please refer to
our website for full warranty information which can be found at http://www.ironman4x4.com/warranty-terms

www.ironman4x4.com PART NO: IDCDC40